Cogen Write Up

8/10/2019 Cogen Write Up

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28.04.2011

INDIAN CANE POWER LTD, UTTUR . 28 MW COGENPLANT DETAIL

Cogeneration!

In simplest terms cogeneration is the process of using a single fuel toproduce more than one form of energy sequence cogeneration of steamand electricity can significantly increase the overall efficiencies of fuelutilization in the process industries. A minimum condition for cogenerationis the simultaneous requirement of heat and electricity in favorable ratio,which is well fulfill in the sugar industriy.Thermodynamics of electricityproduction necessitates the rejection of a large quantity heat to a lower

temperature sink. In normal electricity generation plants, this heat rejectiontakes place in condenser where up to !" of heat in steam is rejected tothe atmosphere. In cogeneration mode, however heat is not wasted and isinstead used to meet process heating requirement. #verall efficiency offuel utilization can thus be increased to $!" or even higher in some cases.India, today, is perhaps the world leader in the implementation of moderncogeneration projects in sugar mill.

"OILER AND AU#ILLARIE$

"oi%er%&

'oiler is a closed pressure vessel e(ceeding capacity more than 2&Ltr'(rwhichmeans to generate steam by utilizing heat from combustion of fuel.

T)*e+ o "oi%er!

1- Water T/e ! A ater t/e /oi%er is a type of boiler in which watercirculates in tubes heated e(ternally by the fire. )ater tube boilers areused for high&pressure boilers. *uel is burned inside the furnace, creating

hot gas which heats water in the steam&generating tubes. +ost of modernboilers are water tube boiler, mean for higher capacity.

2- ire T/e "oi%er !A ire!t/e /oi%eris a type of boiler in which hot gasesfrom a fire pass through one or more tubes running through a sealedcontainer of water. The heat of the gases is transferred through the wallsof the tubes by thermal conduction, heating the water and ultimatelycreating steam.In this type of boiler, flue gas circulates inside the tube
http://en.wikipedia.org/wiki/Thermal_conductionhttp://en.wikipedia.org/wiki/Thermal_conduction


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tubes are surrounded by water. Ancient boilers are *ire tube boilers mean for small capacity.

"oi%er $*eiiation!

-eg o % & /T/&0112+ake % & Therma( 'abcock )ilco( 3une,IndiaType % & 'i drum, bent water tube, natural

4irculation, 5toker fired 'oiler)orking 3ressure % & 6 /g74m1g.8esign pressure % & 9!1 /g74m1g.:ydraulic Test pressure % & 920 /g74m1g.+ain steam temp % & 292;2!44apacity % & 912T3:+ain fuel % & 'agasse&9!!", 6!" imported coal,

$2" Indian coal.Temp control % & $!&9!!" +4-*) temp at m1

.01!"


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:eat loss due to moisture in fuel %& 90.60!":eat loss due to :1 in fuel consumption %& 6.!B":eat loss due to unburnt %& !.099"-adiation uncounted loss %& !.00$"Total =osses %& 1$.66"

'oiler


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2- Regenerati6e t)*e!

Rotating!*%ate regenerati6e air *re(eater! he rotating&plate

design ?consists of a central rotating&plate element installedwithin a casing that is divided into two ?bi-sector type@, three?tri-sector type@ or four ?quad-sector type@ sectors containingseals around the element. The seals allow the element to rotatethrough all the sectors, but keep gas leakage between sectorsto a minimum while providing separate gas air and flue gaspaths through each sector.

$tationar)!*%ate regenerati6e air *re(eater ! The heatingplate elements in this type of regenerative air preheater arealso installed in a casing, but the heating plate elements are

stationary rather than rotating. Instead the air ducts in thepreheater are rotated so as to alternatively e(pose sections ofthe heating plate elements to the up flowing cool air.

AP5 $*eiaiation!

Tube size % & $0.2mm#81.$mmThk2.0mtr=gTotal o of tubes % & $19$:eating 5urface Area % & $20 m1

o of 3asses % & Two*C inlet temp % & 1>B !4

*C out let temp % & 92!

!

4Air Inlet Temp %& 02 !4Air #ut let Temp % & 1!! !4

Note !9@ Air requirement for our 912 T3: 'oiler E 0.$2T3:7Ton of 'agasseF

9B6T3:.

'ottom AirF 906T3:

#*A air F $! T3:

TIP$ OR ENERG7 EICIENC7

$LNO

DE$CRIPTION EICIENC7

9 *lue gas back end temperature reductionby22 0C

'oiler efficiency will rise by1

1 &reduction in e(cess air 'oiler efficiency will rise by


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1

0 1reduction of residual o(ygen at stackgas ?*lue gas@

'oiler efficiency will rise by1

> 199thick scale on water side of pressureparts

fuel consumption will riseby

& to 82 :99thick of soot on e(ternal surface of

pressure partsfuel consumption will riseby2.&

$ :99 dia hole on pipe carrying ;e Data!8esign 3ressure % & 9!.2/g7cm1:ydraulic pressure % & 90.$2/g7cm1

8esign Temp % & 11!!

4o of Gones %& one)orking pressure %& /g7cm1Huantity of steam %& 91.1B> T3:Inlet7 #utlet temp %& 96!79$>.1!4

T/e +i>e!8esign 3ressure %& 902/g7cm1:ydraulic pressure %& 92.2/g7cm18esign Temp %& 9B!!4o of passes %& two

)orking pressure %& 9!!/g7cm1Huantity of *) %& 916.2! T3:Inlet7 #utlet temp %& 99279$2!4:eating surface area %& 9B!m1o of tubes %& 109J9Tube size %& 92.62(96')C(69$$=g


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$tea9 re?ire9ent or 5P (eater @ W 3T2!T1-'Ent(a%*) o 8Ata +tea93$ea+on- @ 10=.2& 31B&!11&-'B=&

@ 8.0 Ton+.

$tea9 re?ire9ent or 5P (eater @ W 3T2!T1-'Ent(a%*) o 8Ata +tea9

3O!+ea+on- @ 101.& 31B&!11&-'B=& @ ;.0 Ton+.

W(ere T1! ee> ater te9*eratre at 5P (eater in%etT2! ee> ater te9*eratre at 5P (eater ot%etW! ee> Water %o.

Dearator% & 8earator is equipment removes corrosive gases such as dissolvedo(ygen and free carbon dio(ide from the boiler feed water by heating feed water

to the operating temperature by steam. 8issolved o(ygen in dearator should beless than 0.00;**9. 8earator works on 3ascal 3artial =aw. As temperature of*) increases, solubility of dissolved o(ygen decreases.

:ydrazine hydrate is dozed in 8earator tank as o(ygen scavenger whichremoves complete o(ygen makes *eed water free from o(ygen.

T)*e+ o Dearator!

Tra) T)*e Dearator


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The typical horizontal tray&type deaerator in *igure 9 has a vertical domed

dearation section mounted above a horizontal boiler feed water storage vessel.

'oiler feed water enters the vertical dearation section above the perforated trays

flows downward through the perforations.=ow pressure dearation steam enters

below the perforated trays and flows upward through the perforations.

$*ra)!t)*e >eaerator!

As shown in *igure, the typical spray&type deaerator is a horizontal vessel which

has a preheating section ?


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:ydraulic test 3ressure %& >.2 /g7cm18esign Temperature %& 92! !4)orking 3ressure %& !.2/g7cm1)orking Temperature %& 992 !48esign code %& on I'-

$tea9 re?ire9ent or Dearator @ W 3T2!T1-'Ent(a%*) o : Ata $tea93$ea+on- @ 12B.2&311&!100-'B&4

@ :TP5.

$tea9 re?ire9ent or Dearator @ W 3T2!T1-'Ent(a%*) o : Ata $tea93O $ea+on- @ 110311&!&&-'B&4

@ 10TP5.

Drat! Induced draught% This is obtained one of three ways, the first being the

+taeetof a heated chimney, in which the flue gas is less densethan the ambient air surrounding the boiler. The denser column of ambientair forces combustion air into and through the boiler. The second methodis through use of a steam jet. The steam jet oriented in the direction of fluegas flow induces flue gasses into the stack and allows for a greater fluegas velocity increasing the overall draft in the furnace. This method wascommon on steam driven locomotives which could not have tall chimneys.T(e t(ir> 9et(o> i+ /) +i9*%) +ing an in>e> >rat an 3ID an-(i( re9o6e+ %e ga+e+ ro9 t(e rnae an> ore+ t(e e(a+tga+ * t(e +ta. A%9o+t a%% in>e> >rat rnae+ o*erate it( a+%ig(t%) negati6e *re++re.

Forced draught% 8raft is obtained by forcing air into the furnace by meansof a fan ?*8 fan@ and ductwork. Air is often passed through an air heaterKwhich, as the name suggests, heats the air going into the furnace in orderto increase the overall efficiency of the boiler. Da9*er+'FD >ri6e+ areused to control the quantity of air admitted to the furnace. *orced draftfurnaces usually have a positive pressure.

Balanced draught% 'alanced draft is obtained through use of both

induced and forced draft. This is more common with larger boilers wherethe flue gases have to travel a long distance through many boiler passes.

The induced draft fan works in conjunction with the forced draft fanallowing the furnace pressure to be maintained slightly below atmospheric.

ID an+ ! 02 No++ake %& *laktwoods+odel %& :A''&&96!&1>>&!$&$&6Ca*ait) ! 4&


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5tatic pressure %& &12!mm of wc8esign temp %& 1!! !4#perating temp %& 962 !4Cas density at operating temp %& !.1>!/g7 m0

C81value %& 06!! /g&m 1

*an 5peed %& 02rpm=ubrication %& !! hrs or 26days

Tota% %e ga+ generation in or /oi%er i+ :B;000 9:'(r B.;B 9:'g o/aga++e

D an+ ! 02 No++ake %& *laktwoods+odel %& :A''&&912&9$0&!>&9&94apacity %& 01.B/g7s or 996.$ m0 7hr

5tatic pressure %& 92mm of )48esign temp %& $! !4#perating temp %& 2! !4Cas density at operating temp %& 9.!2>/g7 m0

C81value %& 9$09 /g&m 1

*an 5peed %& B$2rpm=ubrication %& !! hrs or 26days

Tota% Air %o re?ire9ent or or "oi%er 312&TP5-!!!!!! 1=;9:'(r

"aga++e re?ire> to or "oi%er!!!&4Ton+'5r

$A an+ ! 02 No++ake %& *laktwoods+odel %& :A''&&6!&9!&!1&9&94apacity %& 90.9B/g7s or >.> m0 7hr5tatic pressure %& $2mm of )48esign temp %& 12! !4#perating temp %& 1!2 !4Cas density at operating temp %& .1>!/g7 m0

C81value %& $>! /g&m 1

*an 5peed %& 9>6!rpm=ubrication %& !! hrs or 26days

$A Air %o re?ire9ent or or "oi%er 312&TP5-!!!!!! B=9:'(r

"oi%er ee> Water P9*!


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A boileree> ater *9*is a specific type of pump used to pump feed waterinto a steam boiler. The water may be fresh 8+ water supplied or returningcondensateproduced as a result of the condensation of the steam produced bythe condenser or process. These pumps are normally high pressure units thattake suction from a 8earator and can be of the centrifugal pump type or positive

displacement type.

*eed water pumps range in size up to many horsepower and the electric motorisusually separated from the pump body by some form of mechanical coupling.=arge industrial condensate pumps may also serve as the feed water pumps ineither case, to force the water into the boiler, the pump must generate sufficientpressure to overcome the steam pressure developed by the boiler. This is usuallyaccomplished through the use of a centrifugal pump.

*eed water pumps sometimes run intermittently and are controlled by a floatswitchor other similar level&sensing device energizing the pump when it detects

a lowered liquid level in the boiler. The pump then runs until the level of liquid inthe boiler is substantially increased. 5ome pumps contain a two&stage switch. Asliquid lowers to the trigger point of the first stage, the pump is activated. If theliquid continues to drop ?perhaps because the pump has failed, its supply hasbeen cut off or e(hausted, or its discharge is blocked@, the second stage will betriggered. This stage may switch off the pump equipment ?preventing the boilerfrom running dry and overheating@, trigger an alarm, or both.

Another common form of feed water pumps run constantly and are provided witha minimum flow device to stop over pressuring the pump on low flows. Theminimum flow usual returns to the tank or deaerator.

5team locomotives and the steam engines used on ships and stationaryapplications such as power plants also required feed water pumps. In thissituation, though, the pump was often powered using a small steam engine thatran using the steam produced by the boiler. A means had to be provided, ofcourse, to put the initial charge of water into the boiler ?before steam power wasavailable to operate the steam&powered feed water pump@. The pump was oftena positive displacement pump that had steam valves and cylinders at one endand feed water cylinders at the other endK no crankshaft was required.

Ato9ati reg%ation 6a%6e 3ARC-! The A-4 valve provides protection for

centrifugal pumps during low flow conditions. It recirculates a minimum flowrequirement automatically to the deaerator to prevent the pump from overheatingand causing internal damage. 3ump manufacturers will dictate a pumpLsminimum flow requirement. The A-4 valve will be designed to flow normalcapacities through the main valve and also size the bypass to handle theminimum flow. Additionally, the flow sensing element, a disc, also acts as a checkvalve to prevent reverse flow to the pump.
http://en.wikipedia.org/wiki/Feedwaterhttp://en.wikipedia.org/wiki/Boiler_(steam_generator)http://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Float_switchhttp://en.wikipedia.org/wiki/Float_switchhttp://en.wikipedia.org/wiki/Steam_locomotivehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Power_planthttp://en.wikipedia.org/wiki/Feedwaterhttp://en.wikipedia.org/wiki/Boiler_(steam_generator)http://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Float_switchhttp://en.wikipedia.org/wiki/Float_switchhttp://en.wikipedia.org/wiki/Steam_locomotivehttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Power_plant


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ee> Water P9* ! ! 0: No++ake %& /5' 3umps =td, 3une+odel %& :C4 079>*luid %& *eed water 3ump 5peed %& 1B6! rpm

4apacity %& 6B m0

7hr8esign :ead %& 910!mtr *luid temp %& 992!44oupling make %& -athi+odel type %& =*C 9!0&19!, Cear spacer type=ubrication %& 5ervo system&>$+otor /)7rpm %& 02>/)71B6!

ee> Water Tran+er P9* ! ! 02 No++ake %& /5' 3umps =td, 3une+odel %& 43/ C479!!&12!?5@

*luid %& *eed water 3ump 5peed %& 1B! rpm4apacity %& 9>.2J1$m0 7hr8esign :ead %& 62mtr 4oupling make %& -athi=ubrication %& 5ervo system&>$+otor /)7rpm %& 2/)71B! ?5iemens +ake@

Tra6agrate ! 02

umber of Cate % & 8ual grate

5haft centre to centre distance % & $9!!mmCrate width % & 6$>!mmo of bearings per 5haft % & !> oso of links per chain assembly %& B6oso of chain assembly %& !6os

Anchor bearing location %& 5econd from drive end.Crate casting 1B6 mm7grate bars %&11 os

AssemblyCrate casting 1B6 mm7grate bars %&!6 os

Assembly5kid shoes7grate bar assembly %& 9$ os*abricated grate bar7grate %& B> os

5)>ra%i P9*!

+ake %& Muken


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-ated 3ressure %& >!kg7cm1

8isplacement %&+odel %& 3D- 9T&9&*&-=&1!6!+*C o %& $21

Diretiona% Fa%6e!+ake %& Muken+odel %& 8:C&!$&1'1&2!+anufactured 'y %& Muken India =td, =iscence Muken /ogyoNapan%o Contro% Fa%6e!+ake %& Muken+odel %& *C&!1&0!&116!9+anufactured 'y %& Muken India =td, =iscence Muken /ogyoNapan.

Re%ie Fa%6e!+ake %& Muken+odel %& 'C&!$&3&01+anufactured 'y %& Muken India =td, =iscence Muken /ogyoNapan.

$re ee>er!

Gear Re>er!+ake %& 3'2!Actual -atio %& $>.0#ut put Torque %& 120/gfm

Motor!Type %& :J 9015 +4>8uty %& 590!

Amps %& 99A


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'earing 8< %& $0!6GG 40'earing 8< %& $0!GG40)eight %& !/g

Dr9 ee>er

Gear Re>er!+ake %& 3'=Type %& 99 03 II/) %& .29 %& 2!!-3+1 %& &&&&-atio %& B1.1>79

Motor!

Type %&8uty %& 59er!+ake %& 3'=Type %& 99 03 II/) %& .29 %& 2!!-3+1 %& &&&&-atio %& B1.1>79

Motor!

Type %&8uty %& 59


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rag (ain on6e)or

Gear re>er+ake %& 3'2!

Actual -atio %& B279

#utput torgue % & 162/gm

E- C5IMNE7+ake % 5hilpa 4onstruction 8elhi:eight % B!+5tack dia at bottom I8 % 0.2+5tack dia at bottom #8 % >.B+tr 5tack dia at top I8 % 0.1+5tack dia at top #8 % >.121mtr 4onstruction % -44.

Air Co9*re++or!on lubricant, vertical, double acting, reciprocating air compressor.+ake %& Inger&soll -and+odel %& 6 =3ackage %& >!I59)orking 3ressure %& 9!!35I4apacity %& 9>!4*+.5peed %& 9>$2rpm+otor pulley dia %& 91OO4ompressor 3ulley dia %& 16OO

ote%& 6OO %& 8iameter of piston, P %& stroke length.=%& on lubricant type.

AIR DRIER!

+ake %& Cem


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Item %& 8esiccant Air 8rier+odel %& :=!924apacity %& 92!4*+)orking 3ressure %& 91.2 /g74m1


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4urrent %& 92Amps:ead %& 9>+tr 8ischarge %& >!lps7 9>>m0 7hr.-3+ %& 9>>!-3+Insulation class %& A

AHA5A' ! 40Mtr Motor 5* ! 2&RPM ! 2=00MOC ! CIra9e ! 180

C% Tr P9* to $gar P%ant! ! !1

+odel %& 33:65+4apacity %& 12!+07hr:ead %& >!+tr +otor :p %& $!


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-3+ %& 1B!!+#4 %& 4I*rame %& 12!5

"a %+( *9* ! !1+odel %& 33: 054apacity %& $1+07hr:ead %& 9>+tr +otor :p %& .2-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

a+t %+( *9* ! !1+odel %& 33: 0

4apacity %& 2+

0

7hr:ead %& 1!+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

RO ee> *9* ! !1+odel %& 33: 0+4apacity %& 02+07hr:ead %& 12+tr

+otor :p %& .2-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

Dega+iier *9* ! 0:+odel %& 33: 04apacity %& 0!+07hr:ead %& 02+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

RO (e9ia% %eaning *9* ! 01+odel %& 33: 94apacity %& 1+07hr


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:ead %& 0!+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

DM ater Tr *9* ! 02+odel %& 33: 0+4apacity %& 12+07hr:ead %& 02+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

$ot ater tr *9* to CT ! 02

+odel %& 33:B4apacity %& $2+07hr:ead %& >!+tr +otor :p %& 12-3+ %& 1B!!+#4 %& 4I*rame %& 96!

E%ent Tr P9* ! 02+odel %& 33: 0+4apacity %& 12+07hr

:ead %& 02+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

$%>ge Tr *9*+odel %& 33: 0+4apacity %& 12+07hr:ead %& 02+tr +otor :p %& 9!-3+ %& 1B!!+#4 %& 55&09$*rame %& 901

Anti+a%ant >oing *9*

+ake %& +ilton -oy


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+odel %& A9!+a( #73 %& 1 =3:+a( 3ressure %& 9! /g74m1

$M"$ >oing *9*

+ake %& +ilton -oy+odel %& '91=+a( #73 %& B.2=3:+a( 3ressure %& /g74m1

5CL >oing *9*+ake %& +ilton -oy+odel %& '91=+a( #73 %& B.2=3:+a( 3ressure %& /g74m1


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$LNO

DE$CRIPTIONUNIT JT7'DA7 N O $ APPLICATION

A PRETREATMENT

9*! 4#C=AT

13#=M+ 6962 /C 0 2 )AT22

1990

/C !.!6 992!3: '##5T


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DM PLANT LOW DIAGRAM

4=A-I*I :& 9

Di+(arge ;& 9K'(r

RPM 2=00

W'5P 1&'20

5ea> 40 9

Di+(arge 2&0 9K'(r

RPM 2=00

W'5P 4&'B0

CLARIIED WATER TRAN$ER

PUMP$ TO $OTENER ! 02 No+.

5ea> 40 9

Di+(arge 100 9K'(r

RPM 2=00

W'5P 20'2&

$OT WATER TRAN$ER PUMP

TO COOLING TOWER ! 02 No+.

5ea> 40 9

Di+(arge 100 9K'(r

RPM 2=00

W'5P 20'2&

5=8C< T-A5*

2

$

9 & 1

3ump

o.8osing #utput

=3:

+a(. 3r

kg7cmR

*erric

chloride>!! 6

0 & > 3olyelectro

&lyte01! 6

2 & $ 5odium hy

&pochlorite9! 2

To Trench

To Trench

NEUTRALIATION PIT

PUMP$ ! 02 No+.

5ea> 10 9

Di+(arge &0 9K'(rRPM 2=00

5P &.0

5#*T )AT

5T#-AC

TA/ 1

4A3F 0!!

DA7 $TORAGE

TAN

CAP@ 4,000 9K

5#*T )AT1!44old water temp %& 01!4Inlet wet bulb temp %& 1!4 ?without recirculation allowance@Inlet wet bulb temp %& 16!4 ?with recirculation allowance@5tatic head above basin %& 2.>+tr

8esign live load on fan deck %& 2!!/g7+0

*an speed %& 9$> -3+*an drive transmission %& Cear bo( ?enclosed in oil bath@*an blade construction %&


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8rive motor %& single speed5ize of inlet ' %& 2!!'&> os,92!'&> os.

an ! 4 No++ake %& 3harapur

o of fans per cell %& oneo of blades per cell %& !6*an 5peed %& 9$> -3+'lade diameter at tip %&01!mm:ub diameter reduction gear %& 1>06mm

an Gear "oType of gear reducer %& 'evelo of stages %& Two5eries %& 01.1

Cear ratio %& 6%6%95ervice factor at design ':3 %& .!Transmission &>919&9#il Crade %&5A!

an Motor ! > os+ake %& AlstomDoltage %&>92*requency %& 2!:z

/)7:3 %& >27$!-pm %& 9>2-ated Amps %&6)eight %&062/gs

Reir%ation P9* ! !9 o+ake %& +ather *latType %& !+tr -pm %&9>2

Motor ! !9 o+ake %& A''Doltage %& >92*requency %& 2!:z/)7:3 %& 9271!-pm %& 9>2Ai%%ar) oo%ing ater *9* ! !1 os


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+ake %& +ather *latType %& !!+07hr:ead %&>!+tr -pm %&9>2

Motor ! !1 os+ake %& A''Doltage %& >92*requency %& 2!:z/)7:3 %& 279!!-pm %& 9>2

Main oo%ing ater *9* ! !> os+ake %& +ather *lat pumps =td, 4hinchawad,3uneType %& 9$71!=##T0!+/9

4apacity %& 12!!+

0

7hr:ead %&02+tr -pm %&B66Motor ! !> os, !1 D*8 !1 soft starter+ake %& A''Doltage %& >92*requency %& 2!:z/)7:3 %& 09!7>92-pm %& B66

Miro*roe++or Contro%%e> Treat9ent o oo%ing toer ater!

Indian 4ane 3ower =imited has installed microprocessor controlledtreatment for cooling tower from April th1!9! onwards, cooling tower holdingcapacity% B2! m0 -ecirculation rate% 22!!m07hr.'ac4omber treatment iscontrolled by microprocessors. They ensure%

8elivery of e(act amount of treatment every moment

There is no under dosing or overdosing

o human intervention

The treatment which is once set will continue without any

alteration There is no routine maintenance

No need for frequent chemical analysis.

No chemical TreatmentInitially we have used the following chemicals for controlling the scale, 4orrosion organic fouling. After installation of the microprocessor&controlled treatment


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there is no need to add the following chemicals because =* will take care of thesame.

5ulfuric Acid

5cale Inhibitor

4orrosive Inhibitor

on(idizing 'iocide

'io&8ispersant

5odium hypochlorite.

4ooling Tower chemical treatment cost7month on an average -s, 9, 2!,!!!7&.ow we are saving -s 92, !!!!!7& per annum.

Con+er6ing Water an> Re+ing it(ot treat9ent%

+icroprocessor controlled treatment helps in reducing the blow down even

when the same 4#4 is maintained. This helps in reduction of water used formake up. 'efore =* treatment our cooling tower blow down is around 0!!m07day, after installation of =* treatment our cooling tower blow down isreduced to around 9!! m07day so net saving of make up water 1!! m07day withmaintaining the same 4#4, we say around $!!! m0 of make up water saved permonth. If we convert into cost -s B!!!7& per month for chemical cost -s B!!!7&per month for power consumption cost. Totally -s 96!!!7month net saving.

Net +a6ing+ *er ann9 4ooling tower chemical treatment cost of -s92,!!!!!.!!

3re&Treatment 3ower consumption cost of 4T make up water -s9,B6,!!!.!!

Total savings per annum -s 9$,B6,!!!.!!

ree ro9 Po%%tion'efore installation of =* treatment, blow down water pollutes the environment,=oose the e(pensive chemicals while giving blow down. And also needs constantattention in operation maintenance.

After installation of =* treatment, blow down water is free from harmfulchemicals environment friendly. This water can be used for washing floors,gardening, flushing agricultural usage.

No routine maintenance

nlike the chemical treatment there is nothing to add every day or everyweek. The only consumable is the copper electrode. The replacement is simplewithout interrupting main operation of condensers.


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Prini*%e o UL Treat9ent

ltra =ow *requency ?=*@ waves are at much lower energy levels thanmicrowaves. =* waves strengthen the natural forces within a molecule.

The stronger force helps the molecule to hold the 4a ions even when thetemperature of water reaches 9!! 8eg 4, as in case of industrial process boilers.They do not come out precipitate as hard scale. In our condenser tubes thetemperature are much lower than such boilers only around >1 S 2$ 8eg 4. Thesemolecules hold the 4a ions control hard scale e(cellently.

5o $a%e Corro+ion Contro%%e> /) UL Treat9ent

In the system the water in cooling tower basin flows through a set ofinductor coils which are immersed in the cooling tower water. )hile it is passingthrough these coils the water is treated by =* waves ?ltra =ow *[email protected] increases the intermolecular bond strength controls hard scale formation.It promotes formation of magnetite ?*e0#>instead of *e1#0@ to control corrosion.

4alcium -eduction as shown in the graph.


26/40

$a%e Contro%

"eore UL Treat9ent ater UL Treat9ent

5o 9iro!organi+9+, A%gae $%i9e Contro%%e> /) Co**erioniation4opper ionizationis a water treatment process whereby water is passed througha 4ooling tower fore bay7sump containing si( bundles of copper electrodes. A


27/40

very low voltage is applied across the electrodes to generate positively chargedcopper ions that are released into the water stream. These ions have the abilityto penetrate the protective outer membrane of pathogen cells and disruptmetabolic enzymes, thereby killing the microorganisms to control bacteria, algae slime.

TUR"INE

Huantity %& !9 o

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Type %& :orizental, impulse, +ulti stage, +ulti valveA(ial flow, condensing, e(traction, with

reduction gear.5l o %& 19$>2

Type %& 4B&-&90&B!B-pm792!!-pmInlet steam 3ressure %& 62/g74m1

Inlet steam temp %&29!!49st


28/40

o of 3hase %& !0o of 3oles %& !>Doltage %& 99/D4urrent %& 960Amps*requency %& 2!:z

5peed %&92!!-pm=imiting 5peed %& 96!!+a(3* %&!.6Type of statator connection %& 5tarD>1AType %& T419!Mear of +fg %& 1!!)eight %& $61!!4ooling 5ystem %& I4BA9)

4oolant Temp %& 01

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4+a( temp rise of 5T by -T8 %& 62!44lass of insulation %& A-+&*, *=8&*'rgs?8


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-pm %& 9>2!+otor /)7:3 %& 0!7>!

EOP P9*!Huantity %& !9 o

+ake %& 4olfa( Tushaco 3umps,+otor Cear pump+odel %& -8- 12!+5ize %& $2'*low %&1B!=3+3ressure %& 1.0/g74m1

+otor /)7:3 %& 0.72

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*low %& 91!=3+3ressure %& 1>.0/g74m1

5peed %& 9>2!-3++otor 4ap /w7:p %& B.0791.2

Main Oi% Tan!

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30/40

Huantity %& !1 os*luid %& I5# DC&>$8esign 3ressure %&1 /g74m1

8esign Temp %& 6! !4*iltration -ating %& 9! +icrons

9!!2, IndiaType %& :T&9$!

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Ambient Temp %& 2! !4

Dolts %& >92;9!"4onnection %& 8elta:z %& 2!/)7:3 %& 9271!-3+ %& 9>2!

Amps %& 163f7


31/40

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 9$!+=4>5l o %& 01>1B!8uty %& 59

Insulation %& class *I3 %& 22Ambient Temp %& 2! !4Dolts %& >92;9!"4onnection %& 8elta:z %& 2!/)7:3 %& 0!72!-3+ %& 9>!

Amps %& 2>.23f79!!2, IndiaType %& *&2-atio %& 0!795l o %& 8w799$1>

I73 coupling %& Tyre coupling, *&!#73 coupling %& Ceared coupling

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 991+'>5l o %& 02618uty %& 59Insulation %& I3&22

Ambient Temp %& 2! !4Dolts %& >92;9!"4onnection %& 8elta:z %& 2!/)7:3 %& 270.-3+ %& 9>12

Amps %& .$!3f7


32/40

E#"C!2A!

Gear/o !+ake %& 5hanti Cears =td, 4oimbatore&$>9!!2, India

Type %& :T&9$!-atio %& 02.2795l o %& 8:7!2!0BI73 coupling %& Tyre coupling, *&!#73 coupling %& Ceared coupling

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 991+'>5l o %& 02618uty %& 59

Insulation %& I3&22Ambient Temp %& 2! !4Dolts %& >92;9!"4onnection %& 8elta.:z %& 2!/)7:3 %& 9271!-3+ %& 9>2!

Amps %& 163f79!!2, IndiaType %& :T&9$!-atio %& 09.2795l o %& 8:7!216I73 coupling %& Tyre coupling, *&!#73 coupling %& Ceared coupling

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 99$!+=5l o %& A1!B>!28uty %& 59Insulation %& I3&22

Ambient Temp %& 2! !4Dolts %& >92;9!"4onnection %& 8elta.


33/40

:z %& 2!/)7:3 %& 9271!-3+ %& 9>2!

Amps %& 163f79!!2, IndiaType %& :T&96!-atio %& 09.2795l o %& 8:7!2211I73 coupling %& Tyre coupling, *&!#73 coupling %& Ceared coupling

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 96!+='>5l o %& 0$9218uty %& 59Insulation %& I3&22

Ambient Temp %& 2! !4Dolts %& >92;9!"4onnection %& 8elta.:z %& 2!

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34/40

5l o %&021$!8uty %& 5992;9!"4onnection %& 8elta.:z %& 2!/)7:3 %& 0.72-3+ %& 9>12

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+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J 9015+5l o %& &&&&&&8uty %& 59Insulation %& I3&22

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Gear/o!+ake %& 5hanti Cears =tdType %& *&>-atio %& 0!79

Motor!+ake %& A'' 0 ph squirrel cage induction motor Type%& %& :J9!!='>5l o %& &&&&&&8uty %& 59Insulation %& *92;9!"4onnection %& 8elta.:z %& 2!

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Gear/o !+ake %& 5hanti Cears =td, 4oimbatore&$>9!!2, IndiaType %& *&2-atio %& >!795l o %& 8)799$9BI73 coupling %& 3in bush coupling#73 coupling %& Ceared coupling

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Type%& %& :J 991+'>5l o %& 021$!8uty %& 59Insulation 4lass %& *92;9!"4onnection %& 8elta.:z %& 2!/)7:3 %& 0.72-3+ %& 9>12

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Gear/o !+ake %& 5hanti Cears =td, 4oimbatore&$>9!!2, IndiaType %& *&$-atio %& !795l o %& 8)799$96

I73 coupling %& 3in 'ush coupling#73 coupling %& Ceared coupling

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